Sensor Skid for Autonomous BEV Assembly Guidance
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Solution Overview
Problem
Conventional vehicle assembly processes are inflexible and dependent on conveyor systems, limiting real-time re-routing and adjustment in vehicle assembly, especially for battery-electric vehicles (BEVs).
Innovation Solution
An autonomous vehicle guidance system that uses a temporary sensor skid attached to the BEV, equipped with sensors and a controller, to guide the vehicle through the assembly process, enabling real-time re-routing and dynamic job dispatching without the need for a fixed conveyor system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed conveyor system is used for vehicle assembly, then the assembly process is stable and predictable, but the flexibility and adaptability of the assembly process deteriorates
Solution Approach 1:
The patent applies dynamics by replacing the fixed conveyor system with autonomous vehicles that can dynamically adjust their paths and destinations. The vehicles are equipped with sensors and controllers that enable real-time route planning and re-routing capabilities, allowing the assembly process to adapt flexibly to different models, scheduling changes, and volume requirements while maintaining operational reliability through coordinated control.
Solution Approach 2:
The patent substitutes the mechanical conveyor system with an autonomous navigation system based on sensors, controllers, and communication networks. Instead of relying on fixed mechanical guides and conveyors, the system uses electronic control, GPS-like positioning, and wireless communication to guide vehicles through the assembly process, enabling greater flexibility and adaptability.
2Ease of operation
If a conveyor system is used for vehicle assembly, then the vehicle movement is controlled and guided, but the real-time re-routing and adjustment capability deteriorates
Solution Approach 1:
The autonomous vehicles incorporate dynamic route planning capabilities with sensors and controllers that enable real-time adjustment of movement paths. The system can recalculate optimal routes based on current conditions, work station availability, and scheduling requirements, providing both controlled movement and flexible re-routing capabilities simultaneously.
Solution Approach 2:
The system implements feedback mechanisms where sensors continuously monitor vehicle positions, work station statuses, and environmental conditions. This feedback information is processed by controllers that adjust vehicle routes and speeds in real-time, enabling both precise movement control and adaptive re-routing based on current operational needs.
3Productivity
If the assembly process is designed for specific models and volumes, then the production efficiency is optimized, but the flexibility for model mix and scheduling deteriorates
Solution Approach 1:
The autonomous vehicle platform is designed as a universal system that can accommodate multiple vehicle models and assembly configurations. The vehicles and work stations are equipped with standardized interfaces and adaptive control capabilities that allow the same infrastructure to efficiently handle different models, volumes, and scheduling requirements without requiring dedicated infrastructure for each configuration.
Solution Approach 2:
The system enables dynamic parameter changes in the assembly process by allowing real-time adjustment of vehicle routes, work station assignments, and production scheduling. The control system can modify operational parameters based on model mix requirements, volume changes, and scheduling priorities, maintaining production efficiency while adapting to varying assembly needs.
Data Source
AI summary
An autonomous vehicle guidance system enables a partially assembled battery-electric vehicle (BEV) to be guided through an assembly process with the temporary addition of a sensor skid. The partially assembled BEV includes a vehicle body, a vehicle controller coupled to the vehicle body, a battery electrically coupled to the vehicle controller, a sensor skid configured to be coupled under the vehicle body of the BEV. The sensor skid is configured to guide the BEV through an assembly process. The sensor skid includes a skid body configured to be coupled under the vehicle body of the BEV and a plurality of sensors coupled to the skid body. The sensor skid includes a skid controller in communication with the sensors and the vehicle controller. The skid controller is coupled to the sensor skid.